Multi-Material Orthodontic Aligners for Precise Force Distribution
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Solution Overview
Problem
Prior orthodontic appliances with homogeneous material properties lack control over forces applied to teeth, are sensitive to manufacturing tolerances, and have inaccuracies in tooth movement due to distortion and less-than-ideal attachment template methods.
Innovation Solution
An orthodontic appliance with heterogeneous properties, featuring a stiff outer shell and a compliant inner structure, which allows for customized force and torque application to teeth through localized stiffness variations, and improved attachment placement using direct manufacturing techniques based on 3D scan data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single material is used for the orthodontic appliance, then the manufacturing process is simpler, but the control over forces applied to different teeth is insufficient
Solution Approach 1:
The patent applies local quality by using different materials for different portions of the aligner. Specifically, a first material with first material properties is used for a first portion of the aligner, and a second material with second material properties is used for a second portion. This allows different regions of the aligner to have tailored mechanical properties optimized for their specific functional requirements in tooth movement control.
Solution Approach 2:
The patent employs composite materials by combining a first material and a second material with different material properties in a single orthodontic appliance. This composite construction enables the aligner to exhibit varied mechanical characteristics across different regions, providing superior force control and adaptability compared to homogeneous materials.
2Stability of the object's composition
If a stiff orthodontic appliance is used, then the structure is more stable, but the sensitivity to manufacturing tolerances increases
Solution Approach 1:
The patent addresses tolerance sensitivity by implementing local quality with different materials in different regions. The first material and second material can be selected with different stiffness characteristics, allowing the design to compensate for manufacturing variations in specific high-tolerance areas while maintaining overall structural stability through the composite construction.
Solution Approach 2:
The patent applies parameter changes by varying material properties (such as stiffness, elasticity, or other mechanical parameters) across different portions of the aligner. This allows optimization of force application characteristics and reduces sensitivity to manufacturing tolerances by selecting materials with appropriate property ranges for each functional zone.
3Ease of manufacture
If a homogeneous material is used throughout the appliance, then the manufacturing cost is lower, but the accuracy of tooth movement is reduced
Solution Approach 1:
The patent implements local quality by assigning different materials to different portions of the aligner based on their specific functional requirements. This localized material differentiation enables precise control over force application and tooth movement accuracy in critical areas while maintaining cost-effectiveness by using material variations only where necessary rather than throughout the entire appliance.
Solution Approach 2:
The patent utilizes composite materials to achieve enhanced tooth movement accuracy. By combining a first material and a second material with different properties, the aligner can provide customized mechanical characteristics in different regions, improving the precision of force application and tooth movement control compared to homogeneous materials.
4Stability of the object's composition
If the appliance material is uniformly stiff, then the force generation is more consistent, but the distribution of force to individual teeth is less controllable
Solution Approach 1:
The patent applies local quality by using different materials in different portions of the aligner. This allows the first material to provide consistent force generation in regions where stability is prioritized, while the second material enables customized force distribution and control in regions requiring adaptability for specific tooth movement patterns.
Solution Approach 2:
The patent employs composite materials to simultaneously achieve force generation consistency and force distribution control. The combination of first material and second material with different properties allows the aligner to maintain overall structural stability for consistent force generation while providing localized variations in mechanical characteristics for precise force distribution to individual teeth.
Data Source
AI summary
An orthodontic appliance may include an outer shell having a plurality of cavities shaped to receive the patient's teeth and generate one or more of a force or a torque in response to the appliance being worn on the patient's teeth. The orthodontic appliance may also include an inner structure having a stiffness different than a stiffness of the outer shell. The inner structure can be positioned on an inner surface of the outer shell in order to distribute the one or more of a force or a torque to at least one tooth received within the plurality of cavities.